Food Manufacturing Unit 2

Question 1

FM1

Customer trends/demands

Answer 1

Customer Trends/ Demands WHAT M BEGS
 Add a food example for each
 W = willingness to try new foods
 H = health and Higher Education
 A = aged and small families
 T = technology

M = mum multicultural

B = busier lifestyle
E = environmental
G = geographic location
S = sensory appeal - texture, flavour, aroma,

Question 2

FM2

What is a Raw material

Raw material specification

Why is it important to conduct raw material specification?

Answer 2

What is a Raw material
Product ingredients e.g. fruit and veg
Processing materials e.g. steam and water
Food additives e.g. emulsifiers, starches, colours
Packaging materials e.g. bottles and cans
Raw material specification (Know a food example - AT1 Jam)
Descriptions/Specifications of Raw Material
Test for each specified characteristic
Sampling method for the material
Action - accept or reject based on test results/ start procedures to control the problem to prevent further deterioration

There is no value in specifying a characteristic unless it can be tested

Question 3

FM3

Why use Food additives?

p AND q

Answer 3

Why use food additives? p AND q

Add an example for each

Preserve food
Improve appearance, taste
Improve nutritional value 
Meet special dietary needs
Improve quality

Question 4

FM4

Advantages of using International code numbering system SIT

What role does FSANZ play in the use of Food Additives in Australia?

Answer 4

What is a Raw material

• Product ingredients e.g. fruit and veg
• Processing materials e.g. steam and water
• Food additives e.g. emulsifiers, starches, colours
• Packaging materials e.g. bottles and cans

Raw material specification (Know a food example - AT1 Jam)
Descriptions/Specifications of Raw Material:
- Test for each specified characteristic
- Sampling method for the material
- Action - accept or reject based on test results/ start procedures to control the problem to prevent further deterioration

There is no value in specifying a characteristic unless it can be tested

Question 5

FM6

Advantages of using additives to food

VC 4 S

Answer 5

Advantages of using additives to food

Can sense very shelf-safe nutrients
 Improved:
- Consistency of food
- Sensory properties - texture, flavour appearance, aroma
- Variety of food available
- Shelf life thus reduces waste
- Safe food
- Specific nutrients fortification

Question 6

FM7

Disadvantages of using additives to food

Answer 6

Disadvantages of using additives to food DAD RAN

D = discourages eating fresh
A = amounts used is unknown
D = deceives the customer

R = reactions adverse
A = affect behaviour
N = not natural (mostly)

Question 7

FM8

Levels of Food Production - Small
Raw Materials 
Quality Control (QC)
Equipment
Staff
Output
Distribution

Answer 7

Raw Materials - 2-day supply
Quality control (QC):
- Little/no technical equipment
- Q.C done by visual inspection
- No lab and less documentation

Equipment:

• Domestic style/size hand-held mechanical appliances
• Hand-held mechanical appliances.

Staff – multi-skilling of fewer people

Output:

• Small product range produced over 1 week novelty/niche products
• Novelty/niche products
• Less unit operations and basic packaging

Distribution - Small delivery vans

Question 8

FM9

Levels of Food Production - Large
Raw Materials
Quality Control (QC)
Equipment
Staff
Output
Distribution

Answer 8

Raw Material - Large stockpile as warehoused under controlled temp. conditions

Quality Control (QC)

• Q.C managers
• Food technologists & lab technicians
• Comp. controlled systems.
• H.A.C.C.P control/ documentation

Equipment:
- Hi-tech, continuous flow, computer/robotic systems.
Industrial cleaning/sanitization. Stainless Steel.

Staff - Extensive & high qualified to lesser skilled range

Output:

• Large production in batches
• 24/7 incl. 1-2 processing stages and hi-tech packaging.
• Fast

Distribution - Own logistics system and truck fleet w/ cold chain.

Question 9

FM10

Levels of Food Production - Manual
Characteristics

Answer 9

Characteristics

• Person physical handles the raw materials or food product.
• Most commonly used in small scale production.
  Minimal mechanical equipment is used e.g. food processor, electric mixers

Question 10

FM11

Levels of Food Production - Manual

Pros Cons

Answer 10

Pros

• Hand-made’
• Sense of control
• More skilled workers - - Flexibility in menu/food items
• Lower supply costs.
• Quality control determined by the individual

Cons

• Labour-intensive.
• Safety risk to people and of food contamination.
• Smaller batches.
• Inconsistency.
• More susceptible to human error.
• Large ongoing staff training cost.
• Time consuming and costly to produce reports.
• Lack of security.

Question 11

FM12

Levels of Food Production - Automated/Computerised Characteristics

Answer 11

Automated

• Uses specially designed machines to control processing on a large scale.Uses repetitive actions, pre-determined conditions to ensure product standardisation.
• Fully automated production may control all processes - from mixing to packaging and labelling.
  e. g. Tunnel dryers, centrifuge, blast chillers/freezers.

Computerised known as CAM (Computer-aided Manufacturing).

• Large scale production systems involving the monitoring and controlling of production using sensors and timing systems.
• Sensors note temperature, detect changes or foreign objects such as metals.
• Changes are sent through microprocessor which analyses the data and makes changes if necessary, such as increasing temperature.

Question 12

FM13

Levels of Food Production - Automated/Computerised

Pros	     Cons

Answer 12

Pros

• Reduced labour and need for employees
• Long hours or 24/7 production
• Higher output and faster process
• Conserving of human energy
• Less wastage of materials
• More consistent and standardised production levels
• Automatic shutdowns can be installed to ensure safety argins are maintained
• Generally, a wider target market and distribution area

Cons
- Requires specialist technicians
Impersonal; not 'hand-made'
- Less specialisation Costly
- Requires constant servicing of machinery
- Possibility of malfunctioning

Question 13

FM14

Characteristics of Processing Equipment (S.H.E.D):

Answer 13

S: Safe - machines are to be fitted with safeguards to prevent injury. Equipment in made of stainless steel, which is strong, scratch resistant and impervious. Food technologists/trained operators are responsible for the operations and equipment.

H: Hygienic - an efficient cleaning process called ‘Cleaning in Place’ (CIP) - a mixture of chemicals, heat and water to clean and sanitize machinery, fittings and pipes. Equipment needs to be easy to clean.

E: Effective and:

D: Durable - reliable equipment as breakdowns can be costly as production ceases. Operating 24/7 therefore needs to be energy efficient.

Be able to compare and contrast commercial equipment with domestic e.g. combi oven with domestic oven

Question 14

FM15

Give examples of the processes in each unit operation and what food it is used in food manufacturing.

Answer 14

Separation
Physical- bran from flour.
- Fiitration -cheese curd from water
- Centrifuging - separation of cream from milk)
Chemical - adding renin to curdle milk to make cheese

Size reduction - grinding salt, peanuts to peanut butter, wheat to flour

• Grinding and milling - spices for a curry.
• Cutting, slicing, dicing and grating - Pre-cut stir-fry vegetables, bags of grated cheese

Mixing - beating egg white to make pavlova, kneading bread

Heating - convection, conduction and radiation

• Blanching (scalding vegetables in boiling water or steam for a shorttime to stop enzyme activity) - vegs before freezing
• HTST High temperature short time - pasteurize milk and juices.
• Canning and bottling - tin fruit, jam
• Baking - bread, cakes, biscuits
• Evaporation -tomato paste.

Dehydration - remove moisture from to increase shelf life.

• Cabinet - fruit and vegetables
• Tunnel - meat, vegetables,fruit
• Sun - tomatoes and grapes
• Spray - instant coffee, powdered milk

Cooling
Chilling-slow down or stop microorganisms activity
Freezing:

• Air blast - frozen meals, fruit and veg
• Plate - meat and poultry
• Blast - fish and seafood
• Limmersion freezers - ice cream

Need to know the process and the name of the industrial and domestic

Question 15

FM18

Flow Process Charts
Definition
Symbols and meaning

Answer 15

Define - A flow process chart is a graphic representation of production processes involved in the manufacture of a specific product.

Operation - Operations are when raw materials are deliberately changed physically, chemically or prepared for another operation e.g. via heating.

Inspection - The product is compared to a standard by checking, sampling, examining, and measuring E.g. recording pasteurization temperature.

Transportation - Move materials from one place to another E.g. forklifting apple pallets.

Delay - Conditions don’t allow next step of process to occur, or next

D production step that doesn’t happen immediately E.g. shortcomings in process design, wait for yeast react.

Storage - The product is kept under controlled conditions before selling E.g. canned beans on shelf.

Know an example - e.g. jam

Question 16

FM19

Quality Management System Define

Answer 16

Quality Management System: a set of polices, processes and procedures required to plan and execute a safe and reliable food supply for consumers.

• Quality management aims to control all aspects of food production production planning, development, marketing, servicing.
• Manufacturers adopt preventative methods (quality management systems)torectifyanyrecurring issues, possible hazards, or changes in quality that may arise.
• Quality standards are set by manufacturers to maintain the standard of their products, ensure safe and hygienic production, adherence to laws and regulations, the earning of profit but most significantly, the overall satisfaction of consumers.
• All quality management systems must be documented and have proper records to cover the company and consumers for insurance and reasons of reliability.

Question 17

FM20

List 5 examples of quality management systems used in industrial practices

Answer 17

Good Manufacturing Practices (GMP) - is a system for ensuring all products are consistently produced and controlled according to quality standards. The GMP is designed to reduce the risk involved in food production that cannot be eliminated through testing the final product.
International Organisation for Standardisation (ISO) - 22000:2015 is a specific set of guidelines for food safety management. In 2008 a number of children died, and ill after drinking milk contaminated with melamine. In response the ISO and International Diary Federation prepared technical specification ISO/TS15495, which determines the presence of melamine
Work Health and Safety (WHS) - see next card
HACCP - see next card
Safety and Hygiene - next card

Question 18

FM21
Quality Management System

Work Health and Safety (WHS)

Answer 18

Instructing or training employees on safety issues.

Providing well-maintained equipment that functions efficiently.

Providing a safe working environment that adheres to the Act - A safe working environment includes proper on- the-job training, first aid provisions, correct storage of dangerous chemicals, ventilation, washroom facilities, adequate lighting

Over 20 employees in the workplace a WH&S committee must be made

Responsibility of employees under WH&S guidelines to:

• Wear proper protective clothing.
• Use equipment as instructed.
• Provide notification of accidents.
• Take care of the health and safety of others.
• Accidents are often the result of unskilled/untrained workers, rushed work, poor maintenance of equipment or working environment

Question 19

FM22

HACCP

Answer 19

HACCP - Hazard Analysis and Critical Control Points

Internationally recognised food safety and management system used by businesses as it is scientifically sound and adaptable to individual companies.

Principles

1. Analyse hazards:

Analyse the whole food production process and identify hazards to the safety of food.

2. Determine the critical control points where hazards can be controlled or eliminated:
   - Purchase of raw material.
   - Cold storage of raw material cooking
   - Cold and hot holding of prepared foods.
3. Establish limits for critical control points.

• cooking temperature cooking time
• Physical properties (food colour, appearance, texture etc.)

4. Establish monitoring procedures (visual inspection and physical measurement) for CCPs.
   - Assure food meets the limits set.
   - Specify frequency and time of monitoring procedure.
5. Establish corrective actions in advance for CCPs so as to correct deviations of the limits quickly and prevent unsafe products
6. Establish verification procedures to ensure that the HACCP system is functioningproperly
7. Establish a record system - A HACCP system should be supported by comprehensive, effective and accurate records for reference and review food product safety, process steps, food storage, monitoring and corrective action